JLG 45e Operator Manual

Operators and Safety Manual

Model

30e 35e

n35e

40e

n40e

45e

3120742

August 14, 2001

ANSI

– JLG Lift –

FOREWORD

This manual is a ve ry important tool! Keep it with the machine at all times. The purpose of this manual is to provide owners, users, operators, lessors, and lessees with the precautions

and operating procedures essential for the safe and proper machine operation for its intended purpose. It is important to st ress p rope r mac hine u sage at all t imes. All infor matio n in this m anu al must be re ad and under stood before any attempt is made to operate the machine.

Because the manufacturer has no direct control over machine operation and application, proper safety practices are the resp onsibility of the owner s, users, operators, lessors, and lessees.

All instructions in this manual are based upon the use of the machine under proper operating conditions, with no deviations from the original design. Any alteration or modification of the machine is strictly forbidden without written approval from JLG Industries, Inc.

Due to continu ous p rod uct im provm ents , JLG Indu stries , In c. re serv es th e rig ht to make specif icat ion c hange s without prior notification. Contact JLG Industries, Inc. for updated information.

3120742 – JLG Lift – d

FOREWORD

SAFETY ALERT SYMBOLS AND SAFETY SIGNAL WOR DS

This is the Safety Alert Symbol. It is used to alert you to the potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death

The Safety Alert Symbol will be used with the appropriate Safety Signal Word of “DANGER” “WARNING” or “CAUTION” to a potential hazard and designate a level of seri ousness. The Safety Signal Words are insert ed throughout this manual in Black/White. On the machine, the Safety Signal Words will have either a Red, Orange, or Yellow background as part of a safety sign or decal. The “DANGER”, “WARNING”, and “CAUTION” Safety Signal Words, definitions, and associated colors are as follows:

Indicates an imminently hazardous situation which, if not avoided, will word is used in the most extreme cases. When installed on the machine, this Signal Word will have a Red background as part of a decal.

result in serious injury or death. This signal

Indicates a potentiality hazardous situation which, if not avoided, could installed on the machine, this Signal Word will have an Orange background as part of a decal.

Indicates a potentiality hazardous situation which if not avoided, may be used to alert against unsafe practices. When installed on the machine, this Signal Word will have a Yellow background as part of a decal.

The “IMPORTANT” Safety Signal Word may also appear in this manual or on the machine. This Safety Signal Word typically will not appear with the Safety Alert Symbol, but contains important information that must be followed for safe and proper operation, The “IMPORTANT” Safety Signal Word definition and associat ed co lor is as follows.

Indicates procedures esse ntial for s afe operation and w hich, if not followed, may result in a machine malfunctioned damage. When installed in a machine, this Si gn al W ord will ha ve a Green backgroun d as part of a decal.

result in serious injury or death. When

result in minor or moderate injury. It may also

e – JLG Lift – 3120742

FOREWORD

ALL SAFETY-RELATED BULLETINS MUST BE ACCOMPLISHED ON THIS PRODUCT. JLG INDUSTRIES, INC. MAY HAVE ISSUED SAFETYRELATED BULLETINS FOR THIS JLG PRODUCT. CONTACT JLG INDUSTRIE S, INC. OR THE LOCAL AUTHORIZED JLG DEA LER FOR INFORMATION REGARDING SAFETY-RELATED BULLETINS WHICH MAY HAVE BEEN ISSUED FOR THIS PRODUCT.

FOR THE PURPOSE OF RECEIVING SAFETY-RELATED BULLETINS, IT IS IMPORTANT THAT THE CURRENT OWNER OF THIS UNIT ENSURES JLG INDUSTRIES, INC. HAS UPDATED OWNERSHIP INFORMATION. CONTACT JLG INDUSTRIES, INC. TO ENSURE THAT THE CURRENT OWNER RECORDS ARE UPDATED AND ACCURATE.

JLG INDUSTRIES, INC. MUST BE NOTIFIED IMMEDIATELY IN ALL INSTANCES WHERE JLG PRODUCTS HAVE BEEN INVOLVE D IN AN ACCIDENT INVOLVING BODILY INJURY OR DEATH OF PERSONNEL OR WHEN SUBSTANTIAL DAMAGE HAS OCCURRED TO PERSONAL PROPERTY OR THE JLG PROD UCT

FOR:

•Accident Reporting

•Product Safety Publications

•Current Owner Updates

•Questions Regarding Product Safety

•Standards and Regulations Compliance Information

•Questions Regarding Special Product Applications

•Questions Regarding Product Modi fications

CONTACT:

Product Safety and Reliability Department JLG Industries, Inc. 1 JLG Drive McConnellsburg, PA 17233

Toll Free: 877-JLG-SAFE

877-554-7233

E-mail: ProductSafety@JLG.com

3120742 – JLG Lift – f

FOREWORD

September 1997 - Original Issue August 14, 2001 Revised

REVISION LOG

g – JLG Lift – 3120742

TABLE OF CONTENTS

TABLE OF CONTENTS SUBJECT - SECTION, PARAGRAPH PAGE NO. SECTION - FOREWORD

SECTION 1 - SAFETY PRECAUTIONS

1.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1

1.2 Pre-operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1

1.3 Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2

1.4 Towing, Lifting, And Hauling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5

1.5 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-6

SECTION 2 - PREPARATION AND INSPECTION

2.1 GENERAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1

2.2 PREPARATI O N FO R USE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 -1

2.3 DELIVERY AND FREQ U E N T I N SP ECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1

2.4 Daily Walk-Around Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-5

2.5 dAILY FUN CTIONAL CHECK.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-9

2.6 TORQUE REQUIREMENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-9

2.7 BATTERY MA I N TEN AN C E A N D CH ARGING.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-10

SECTION 3 - USER RESPONSIBILITIES AND MACHINE CONTROLS

3.1 GENERAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1

3.2 PERSONNE L TRAINING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1

3.3 OPERATING CHARACTERISTICS AND LIMITATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2

3.4 CONTROL S AND INDICATORS.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2

SECTION 4 - MACHINE OPERATION

4.1 DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1

4.2 GENERAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1

4.3 MOTOR OP ERATION.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1

4.4 TRAVELIN G ( Driv ing). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2

4.5 STEERING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2

4.6 PLATFORM.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-3

4.7 BOOM.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-3

4.8 BOOM FUNCTION SPEEDS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-4

4.9 SHUT DOWN AND PARK.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-4

4.10 MACHINE TIE DOWN.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-4

4.11 MACHINE LIFTIN G.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-6

SECTION 5 - OPTIONAL EQUIPMENT

5.1 MOTION ALARM.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1

5.2 FOAM FILL E D TIRES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1

5.3 NON-MA RKING TIRES.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1

5.4 ROTATI N G BEACON. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1

5.5 TILT ALARM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1

5.6 WHEEL COV ERS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1

5.7 BATTERY PA CKS.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1

5.8 PLATFOR M LI GH TS.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1

5.9 Control Console Cover.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1

5.10 CYLINDER BELLOW S. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1

5.11 STEEL HOOD COVERS. ( 30 e le ctric). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1

5.12 WORK PLATFORM. (35/40/n40/45 elec t r ic) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1

5.13 SIMULTANEOUS DRIVE / LIFT / STEER. (n40/40/45 electric). . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1

3120742 – JLG Lift – i

TABLE OF CONTENTS (Continued)

SECTION 6 - EM ERGENCY PROCEDURES

6.1 GENERAL.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1

6.2 EMERGENCY TOWING PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1

6.3 EMERGENCY CONTR OLS AND THEIR LOCATIONS.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 -1

6.4 EMERGENCY OPER AT ION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-2

6.5 INCIDENT NOTIF I CA TION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-2

SECTION 7 - INSPECTION AND REPAIR LOG

LIST OF FIGURES

FIGURE NO. TITLE PAGE NO.

2-1. Boom Nomenclature. (30/35/n35 electric) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3

2-2. Boom Nomenclature. (40/n45/45electric). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-4

2-3. Daily walk-around Inspect ion. (Sheet 1 of 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-6

2-4. Lubri cation Chart - 30 electri c. (Sheet 1 of 6). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-11

2-4. lubri cation Chart - 30 electric. (Sheet 2 of 6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-12

2-4. Lubri ca t ion Chart - 35/n35 electric. (Sheet 3 of 6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-13

2-4. Lubri ca t ion Chart - 35/n35 electric. (Sheet 4 of 6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-14

2-4. Lubri cation Chart - 40/n40/45 ele ct r ic. (Sheet 5 of 6). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-15

2-5. Torque Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-17

3-1. Position of Least Forward Stability, 30 electric. (Sheet 1 of 3) . . . . . . . . . . . . . . . . . . . . . . . . . . .3-3

3-1. Position of Least Fo rward Stability, 35/n3 5 el e ctric. (Sheet 2 of 3). . . . . . . . . . . . . . . . . . . . . . . .3-4

3-1. Position of Least Forward Stability, 40/n40/45 electric. (Sheet 3 of 3) . . . . . . . . . . . . . . . . . . . . .3-5

3-2. Position of Least Bac kward Stability, 30 e l e c t r ic . (S he e t 1 of 3). . . . . . . . . . . . . . . . . . . . . . . . . .3-6

3-2. Positio n of Least Backward Stability, 35/n35 electr ic. (Sheet 2 of 3) . . . . . . . . . . . . . . . . . . . . . .3-7

3-2. Positio n of Le a s t Ba ck ward Stability, 40/n40/45 electric. (Sheet 3 of 3). . . . . . . . . . . . . . . . . . . .3-8

3-3. Ground Control Station, 30 ele ct r ic. (Sheet 1 0f 4). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-9

3-4. Platform Control Consol e .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13

4-1. Grade a nd Side Slopes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 -3

4-2. Upright Positioning Models 40e and 45e.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-5

4-3. Chassis & Platform Tie Down. (All Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-7

4-4. Lifting Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-8

LIST OF TABLES

TABLE NO. TITLE PAGE NO.

1-1 Minimum Safe Approach Dist ances (M.S.A.D.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4

7-1 Inspection and Repair Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

ii – JLG Lift – 3120742

SECTION 1 - SAFETY PRECAUTIONS

SECTION 1. SAFETY PRECAUTIONS

1.1 GENERAL

This section outlines the necessary precautions for proper and safe machine usage and maintena nce. In order to promote proper machine usage, it is mandatory that a daily routine is established based on the content of this manual. A maintenance program, using the information provided in this manual and the Service and Maintenance Manual, must also be established by a qualified person and must be followed to ensure that the machine is safe to operate.

The owner/user/operator/lessor/lessee of the machine should not accept operating responsibility until t his manual has been read, training is accomplished, and operation of the machine has been completed under the supervision of an experienced and qualified operator.

The owner/user/operator/lessor/l essee must be familiar with Sections 6, 7, 8, 9, 10 of ANSI A92.5-1992. These sections contain the responsibilities of the owner, user, operator, lessor, and lessee concerning safety, training, inspection, maintenance, application, and operation.

If there are any questions with regard to safety, training, inspection, maintenance, application, and operation, please contact JLG Industries, Inc. (“JLG”).

FAILURE TO COMPLY WITH TH E SAFETY PRE CAUTIONS LIS TED IN THIS MANUAL COULD RESULT IN MACHINE DAMAGE, PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.

1.2 PRE-OPERATION Operator Training and Knowledge

• The Operators and Safety Manual must be read and understood entirety before operating the mach in e. For clarification, questions, or additional information regarding any portions of this manual, contact JLG Industries, Inc.

• An operator must not a ccept operating resp onsibilities until adequate training has been given by competent and authorized persons.

• Allow only those authorized and qualified personnel to operate the machine who have demonstrated that they understand the safe and proper operation and maintenance of the unit.

• Read, understand, and obey all DANGERS, WARNINGS, CAUTIONS, and operating instructions on the machine and in thi s manual.

• Ensure that the machine is to be used in a manner which is within the scope of its intended application as determined by JLG.

• All operating personnel must be familiar with the emergency controls and emergency operation of the machine as specif ied in this manual.

• Read, understand, and obey all applicable employer, local, and governmental regulations as they pertain to your utilization and applic ation of the machine.

Workplace Inspection

• Precautions to avoid all hazards in the work area must be taken by the user before operation of the machine.

• Do not operate or raise the platform from a position on trucks, trailers, railway c ars, floa ting vessels , scaffolds or other equipment unless the application is approved in writing by JLG.

• Before operation, check work area for overhead hazards such as electric lines, bri dge cranes, and o ther potential overhead obstructions.

• Check floor surfaces for holes, bumps, drop-offs, obstructions, debris, concealed holes, and other potential hazards.

• Check the work area for hazardous locations. Do not operate the machine in hazardous environments unless approved for that purpose by JLG.

• Ensure that the ground conditions are adequate to support the maximum tire load indicated on the tire load decals located on the chassis adjacent to each wheel.

• Do not operate the machine when wind conditions exceed 30 mph (12.5 m/s).

• This machine can be operated in nominal ambient temperatures of 0

JLG to optimize operation outsid e of this t emperature range.

F to 104o F (-20o C to 40o C). Consult

3120742 – JLG Lift – 1-1

SECTION 1 - SAFETY PRECAUTIONS

Machine Inspection

• Do not operate this machine until the inspections and functional checks have been performed as specified in the Preparation and Inspection section of this manual.

• Do not operate this machine until it has been serviced and maintained according to the maintenance and inspection requirements as specified in the machine’s Service and Maintenance Manual.

• Ensure the footswitch and all other safety devices are operating properly. Modification of these devices is a safety violation.

MODIFICATIO N OR ALT ERATION OF AN AERI AL WORK P LATFORM SHALL BE MADE ONLY WITH PRIOR WRITTEN PERMISSION FROM THE MANUFACTURER

• Do not operate any machine on which the safety or instruction pla ca r ds or de c al s are missing or illegible.

• Check the machine for modifications to original components. Ensure that any modifications have been approved by JLG.

• Avoid accumulation of debris on platform floor. Keep mud, oil, grease, and other slippery sub stances fro m footwear and platform deck.

• Do not allow personnel to tamper with or operate the machine from the gro und with pe rsonnel in t he platform, except in an emergency.

• Do not carry materials directly on platform railing unless approved by JLG.

• When two or more persons are in the platform, the operator shall be responsible for all machine operations.

• Always ensure that power tools are properly stowed and never left hanging by their cord from the platform work area.

• When driving, always position boom over rear axle in line with the direction of travel. Remember, if boom is over the front axle, the direction of steer and drive will be opposite from normal operation.

• Do not assist a stuck or disabled machine by pushing, pulling, or by using boom functions. Assist only by pulling at the chassis tie-down lugs.

• Do not place boom or platform agains t any s tructure to steady the platform or to support the structure.

• Stow boom and shut off all power before leaving machine.

1.3 OPERATION General

• Do not use the machine for any purpose other than positioning per sonnel, their tool s, and equipment.

• Before operation, the user must be familiar with the machine capabilities and operating characteristics of all functions. (Ref. Table 4-1 Machine Operation.)

• Never operate a malfunctioning machine. If a malfunctions occurs, shut down the machine. Remove the unit from service and notify the proper authorities.

• Do not remove, modi fy, or disable the foots wit ch or a ny other safety devices.

• Never slam a control switch or lever through neutral to an opposite direction. Always return switch to neutral and stop before moving the switch to the next function. Operate controls with slow and even pressure.

• Hydraulic cylinders should never be left at end of travel (fully extended or fully retracted) before shutdown or for long periods of time. Always “bump” control in opposite direction s lightly wh en fu nction re aches end of travel. This applies both to machines in operation or in the stowed position.

1-2 – JLG Lift – 3120742

SECTION 1 - SAFETY PRECAUTIONS

Trip and Fall Hazards

JLG Industries, Inc. requires that all persons in the platform wear a full body harness with a lanyard attached to an authorized lany ard anchorage point while oper ating this machine. For further information regarding fall protection requirements on JLG products, contact JL G Industries, Inc.

• Prior to operation, ensure all gates are fastened and secured in their proper position. Identify the designated lanyard anchorage point(s) at the platform and securely attach the lanyard. Attach only one (1) lanyard per lanyard anchorage point.

• Platform-to-structure transfers at elevated positions are discouraged. Where transfer is necessary, enter/exit through the gate only with the platform within 1 foot (0.3m) of a safe and secure structure. 100% tie-off is also required in this situation utilizing two lanyards. One lanyard must be attached to the platform with the second lanyard attached to the structure. The lanyard connected to the platform must not be disconnected until such time the t ransfe r to the st ructure i s safe and complete.

• Keep oil, mud, and slippery substances cleaned from footwear and the platform floor.

Electrocution Hazards

• This machine is not insulated and does not provide protection from contact with an electrically charged conductor.

• Keep both feet firmly positioned on the platform floor at all times. Never position ladders, boxes, steps, planks, or similar items on unit to pro vide additional reach for any purpose.

• Never use the boom assembly to gain access to or leave the platform.

• Use extreme caution when entering or leaving platform. Ensure that the boom is fully lowered. Face the machine when entering or leaving the platform. Always maintain “three point contact” with the machine, using two hands and one foot or two feet and one hand at all times during entry and exit.

• Maintain safe clearance from electrical lines, apparatus, or any energized (exposed or insul ated) parts in accordance with the Minimum Safe Approach Distance (MSAD) as specified in Table 1-1. Allow for machine movement and electrical line swaying.

3120742 – JLG Lift – 1-3

SECTION 1 - SAFETY PRECAUTIONS

Table 1-1.Minimum Safe Approac h Distances (M.S.A.D.)

Voltage Range

(Phase to Phase)

0 to 300V AVOID CONTACT

Over 300V to 50 KV 10 (3)

Over 50KV to 200 KV 15 (5) Over 200 KV to 350 KV 20 (6) Over 350 KV to 500 KV 25 (8) Over 500 KV to 750 KV 35 (11)

Over 750 KV to 1000 KV 45 (14)

• Maintain a clearance of at least 10 ft (3m) between any part of the machine and its occupants, their tools, and their equipment from any ele ctrical line or ap paratus carrying up to 50,000 volts. One foot additional clearance is required for every additional 30,000 volts or less.

MINIMUM SAFE APPROACH

DISTANCE

in Feet (Meters)

• The user should be familiar with the driving surface before driving. Do not exceed the allowable sideslope and grade while driving.

DO NOT MANEUVER MACHINE OR PERSONNEL INSIDE PROHIBITED ZONE (MSAD). ASSUME ALL ELECTRICAL PARTS AND WIRING ARE ENERGIZED UNLESS KNOWN OTHERWISE.

Tipping Hazards

• Ensure that the ground conditions are adequate to support the maximum tire load indicated on th e machine. Do not travel on unsupported surfaces.

• Do not elevate platform or drive with platform elevated while on a sloping, uneven, or soft surface. Ensure machine is positioned on a firm, level and uniformly supported surface before elevating platform or driving with the platform in the elevated position.

• Before driving on floors, bridges, trucks, and other surfaces, check allowable capacity of the surfaces.

• Never exceed the maximum work load as specified on the platform. Distribute loads evenly on platform floor. Keep all loads within the confines of the platform, unless authorized by JLG.

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SECTION 1 - SAFETY PRECAUTIONS

• Keep the chassis of the machine a minimum distance of 2 ft. (0.6m) from holes, bumps, drop-offs, obstructions, debris, concealed holes, and other potential hazards at the ground level.

• Never push or pull the machine or other objects by telescoping or retracting the boom.

• Never attempt to use the machine as a crane. Do not tie-off machine to any adjacent structure. Never attach wire, cable, or any similar items to platform.

• Do not operate the machine when wind conditions exceed 30 mph (12.5 m/s).

• Do not cover the platform sides or carry large surfacearea items in the p latfor m when o peratin g outd oors. The addition of such items increases the exposed win d area of the machine.

• Do not increase the platform size with unauthorized deck extensions or attachmen t s .

• If boom assembly or platform is caught so that one or more wheels are off the ground, all persons must be removed before attempting to free the machine. Use cranes, forklift trucks, or other appropriate equipment to stabilize mach in e and remove person ne l.

Crushing and Collision Hazards

• Approved head gear must be worn by all operating and ground personne l.

• Keep hands and limbs away from boom assembly during operation.

• Watch for obstructions around machine and overhead when driving. Check clearances above, on sides, and bottom of platform when lifting or lowering platform.

• Under all travel conditions, the operator must limit travel speed according to conditions of ground surface, congestion, visibility, slope, location of personnel, and other factors causing hazards of collision or injury to personnel.

• Be aware of stopping distances in all drive speeds. When driving in high speed, switch to low speed before stopping. Travel grades in low speed only.

• Do not use high speed drive in restricted or close quarters or when dr iving in reverse.

• Exercise extreme caution at all times to prevent obstacles from striking or interfering with operating controls and persons in the pla tf orm .

• Ensure that operators of other overhead and floor level machines are aware of the aerial work platform’s presence. Disconnect power to over head cranes. Bar ricade floor area if necessary.

• Avoid operating over ground personnel. Warn personnel not to wo rk , sta nd, o r wa lk un der a r ai sed bo om or platform. Position barricad e s on floor as necessary.

1.4 TOWING, LIFTING, AN D HAULING

• Never allow personnel in platform while towing, lifting, or hauling.

• This machine should not be towed, except in the event of emergency, malfunction, power failure, or loading/ unloading. Refer to the Emergency Procedures section of this manual for emergency towing procedures.

• Ensure boom is in the stowed position and the turntable locked prior to towing, lifting or h auling. The platform must be completely empty of tools.

• When lifting machine, lift only at designated areas of the machine. Lift with lifting equipment of adequate capacity.

• Refer to the Machine Operation section of this manual for lifting information.

• During operation, keep all body parts inside platform railing.

• Use the boom functions, not the drive function, to position the platform close to obstacles.

• Always post a lookout when driving in areas where vision is obstructed.

• Keep non-operating personnel at least 6 ft. (1.8m) away from machine during all driving operations.

3120742 – JLG Lift – 1-5

SECTION 1 - SAFETY PRECAUTIONS

1.5 MAINTENANCE General

This section co ntains general sa fety pre cautions which must be observed during maintenance of this machine. Additional precautions to be observed during machine maintenance are inserted at the appropriate points in this manual and in the Service and Maintenance Manual. It is of utmost importance that maintenance personnel pay strict attention to these precautions to avoid possible injury to personnel or damage to the machine or property. A maintenance prog ram must be establ ished by a qua lified person an d must be follow ed to ensure that the machine is safe.

Maintenance Hazards

• Shut off power to all controls and ensure that all operating systems are secured from inadvertent motion prior to performing any adjustments or repairs.

• Never work under an elevated platform until it has been fully lowered to the full down position, if possible, or otherwise supported and restrain ed from movemen t with appropriate safety props, blocking, or overhead supports.

• Always relieve hydraulic pressure from all hydraulic circuits before loos ening o r removing hyd rauli c components.

• Always disconnect batteries when servicing electrical components or whe n performing weld ing on the machine.

• Shut down the engine (if equipped) while fuel tanks are being filled.

• Ensure replacement parts or components are identical or equivalent to original parts or components.

• Never attempt to move heavy parts without the aid of a mechanical device. Do not allow heavy objects to rest in an unstable position. Ensure adequate support is provided when raising components of the machine.

• Remove all rings , watch es, and j ewelry when pe rform ing any maintenance. Do not wear l oose fitt ing clothing or long hair unrestrained which may become caught or entangled in equipment.

• Use only clean approved non-flammable cleaning solvents.

• Never alter, remove, or substitute any items such as counterweights, tires, batteries, platforms or other items that may re duce or affe ct the over all weight or stability of the machine. Reference the Service and Maintenance Manual for the weights of critical stability items.

MODIFICATI ON OR ALT ERATION O F AN AERI AL WORK P LATFORM SHALL BE MADE ONLY WITH PRIOR WRITTEN PERMISSION FROM THE MANUFACTURER

Battery Hazards

• Always disconnect batteries when servicing electrical components or whe n performing weld ing on the machine.

• Do not allow smoking, open flame, or sparks near battery during charging or servicing.

• Do not contact tools or other metal objects across the battery terminals.

• Always wear hand, eye, and face protection when servicing batteries. Ensure that batte ry acid does not come in contact wi th skin or clothing.

BATTERY FLUID IS HIGHLY CORROSIVE. AVOID CONTACT WITH SKIN AND CLOTHING AT ALL TIMES. IMMEDIATELY RINSE ANY CONTACTED ARE A WITH CLEAN W ATER AND SEE K MEDICAL ATTENTION.

• Charge batteries only in a well ventilated area.

• Avoid overfilling the battery fluid level. Add distilled

water to batteries only after the batteries are fully charged.

1-6 – JLG Lift – 3120742

SECTION 2 - PREPARATION AND INSPECTION

SECTION 2. PREPARATION AND INSPECTION

2.1 GENERAL.

This section provides the necessary information needed by those personnel that are responsible to place the machine in operation readiness, and lists checks that are performed prior to use of the machine. It is important that the information contained in this section be read and understood before any attempt is made to operate the machine. Ensure that all the necessary inspections have been completed successfully before placing the m achine into service. These procedures will aid in obtainin g maximum service life and safe oper a t ion.

SINCE THE MACHINE MANUFACTURER HAS NO DIRECT CONTROL OVER THE FIE LD INSPECTION AND MAINTENANC E, SAFETY IS THE RESPONSIBILITY OF THE OWNER/OPERATOR.

2.2 PREPARATION FOR USE.

Before a new machine is put into operation it must be carefully inspected for any evidence of damage resulting from shipment and in specte d period ically therea fter, as outlined in Delivery and Frequent Inspection (see section 2-3). (During initial start-up and run,) the unit should be thoroughly checked for hydraulic l eaks. A check of all components should be made to assure their security.

All preparation n ecessar y to pl ace the machin e in oper ation readiness stat us is the respo nsibil ity of man ageme nt personnel. Preparation requires good common sense, (i.e. lift works smoothly and brakes operate properly) coupled with a s eries of visu al ins pectio ns. The m andator y requirements are given in the Daily Walk Around Inspection (see section 2-4).

It should be assured that the items appearing in the Delivery and Frequent Inspection and Functional Check are complied with prior to putting the machine into service.

NOTE: ANSI/SIA 92.5-1992 also requires an annual inspec-

tion to be perfo rmed. See ann ual mac hine ins pectio n report CGF330.

The following checklist provides a systematic inspection to assist in detecting defective, damaged, or improperly installed parts. The checklist denotes the items to be inspected and cond it io ns t o e xam ine.

Frequent inspection shall be performed every 3 months or 150 hours whichever come first, or more often when required by environment, severity, and frequency of usage.

This inspection checklist is also applicable and must be followed for all machines that have been in storage or for all machines that have been exposed to harsh or changing climates.

These checks are also to be performed after maintenance has been performed on the machine.

Chassis.

1. Check front tires and wheel assemblies for loose or worn spindles, components and hardware for security, tires for wear, damage and proper inflat ion.

2. Check front axle for loose, missing, and worn parts, pivot pin for security.

3. Check steering assembly for loose or bent steer cylinder rods, steer cylinder and hydraulic lines for leaks and security, and hardware for proper installation.

4. Check rear tires and wheel assemblies for security, tires for wear, damage and proper inflation.

5. Check drive hu bs fo r dama ge an d lea ks , and m ot ors and brakes for dama ge.

6. Check oil level in drive hubs by removing ‘fill plug’ on top and ‘check p lug’ on side. Fill from to p with EPGL SAE90 until oil flows from check plug. Replace both plugs.

7. Check valves and hydraulic lines for damage, leak-

2.3 DELIVERY AND FREQUENT INSPECTION.

NOTE: This machine requires periodic safety and mainte-

nance inspections by an authorized JLG Dealer. A decal located on the frame provides a place to record (stamp) inspection dates. Check decal and notify dealer if inspection is overdue.

age and security.

8. Check pump/motor and accessories for damage, loose or missing parts, leakage and security. Check electrical connections for corrosion and tightness and wiring for insulation damage. Check hydraulic filter for condition of element. Replace as required.

9. Check hydraulic reservoir and hydraulic lines for damage, leakage an d se curity.

3120742 – JLG Lift – 2-1

SECTION 2 - PREPARATION AND INSPECTION

10. Check batteries for damage, loose or m issing vent caps, electrical connections for tightness and evidence of corrosion, and electrolyte level. Add only clean distilled water to battery after it has been charged.

Turntable.

11. Check turn tabl e f or dama ge , loos e or mi ssin g part s, and security. Check lift cylinders and hydraulic lines for damage, leakage and security. Check swing drive motor for damage, loose or missing parts, hydraulic lines and component housings for evidence of leakage; worm gear for proper mesh with swing gear.

12. Check swing bearing for damage, wear, lubrication and loose or mi ss ing bearing bolt s.

13. Check valves and hydraulic lines for damage, leakage, security and electrical connections for tightness and evidence of corrosion.

14. Check ground controls for damage, loose or missing parts, security, electrical connections for tightness and evidence of corrosion and wiring for insulation damage. Assure that all switches function properly.

NOTE: JLG recommends replacing the hydraulic filter ele-

ment after th e first 50 hours of operation and then every 300 hours thereafter, unless operating conditions require earlier replacement.

5. Check limit switch connections and plunger for corrosion and security.

6. Check Upright for damage, wear, lubrication, and security.

7. Check Upper Boom lift cylinder and cross pins and hydraulic lines for damage, wear, lubrication, leakage and security.

8. Check Upper Boom pivot pin for damage, wear, lubrication and security.

9. Check Upper Boom for damage, missing parts and security.

10. Check hydraulic lines mounted on upright for damage, leakage and security.

NOTE: The following, (10) thru (12) apply only to the 35 and

n35 electric.

1. Check Upper Boom wear pads for damage, missing parts and security.

2. Check Upper Boom telescope cylinder, cross pins and hydraulic lines for damage, wear, lubrication, leakage and security.

3. Check Platform Leveling Cylinder, cross pins and hydraulic lines for damage, wear, lubrication, leakage and security.

1. Check all cowl and access doors for damage, proper operation and security.

2. Check Lower Boom pivot bushings for lubrication and wear.

3. Check Lower Boom Lift Cylinder and hydraulic lines for damage, leakage and security.

4. Check all pin and shaft retaining hardware for security and wear.

5. Check all electrical cables for damage, loose and corroded connections.

30/35/n35 electric - Boom. (See Figure 2-1)

1. Check Lower Boom and leveling link for damage, missing parts an d security.

2. Check all pin and shaft retaining hardware for security and wear.

3. Check hydraulic lines and electrical cable for damage, missing parts and security.

4. Check limit swi tch connection s and pl unger fo r corrosion and security.

40/n40/45 electric - Boom. (See Figure 2-2)

1. Check Lower Boom and leveling link for damage, missing part s and security.

2. Check all pin and shaft retaining hardware for security and wear.

3. Check hydraulic lines and electrical cable for damage, missing parts and security.

4. Check limit switch connections and plunger for corrosion and security.

5. Check Lower Upright cross pins and hydraulic lines for damage, wear, lubrication, leakage and security.

6. Check Lower Upright for damage, wear, lubrication and security.

7. Check hydraulic lines mounted on upright for damage, leakage and security.

8. Check Mid Boom pivot shaft and lift cylinder for damage, missing parts and security.

2-2 – JLG Lift – 3120742

SECTION 2 - PREPARATION AND INSPECTION

Figure 2-1. Boom Nomenclature. (30/35/n35 electric)

3120742 – JLG Lift – 2-3

SECTION 2 - PREPARATION AND INSPECTION

Figure 2-2. Boom No menclature. (40/n45/45electric)

9. Check al l pin and sh aft ret ainin g hardw are for security and wear.

10. Check Upper Upright, cross pins and hydraulic lines for damage, wear, lubrication, leakage and securi ty.

11. Check Upper Upright for damage , wear, lubrication and security.

12. Check hydraulic lines mounted on upright for damage, leakage and security.

13. Check Upper Boom Lift Cylinder and cross pins and hydraulic lines for damage, wear, lubrication, leakage and security.

14. Check Upper Boom pivot pin for damage, wear, lubrication and security.

15. Check Upper Boom for damage, missing parts and security.

16. Check Upper Boom wear pads for damage, missing parts and security.

17. Check Upper Boom telescope cylinder, cross pins and hydraulic lines for damage, wear, lubrication, leakage and security.

18. Check Platform Leveling Cylinder, cross pins and hydraulic lines for damage, wear, lubrication, leakage and security.

Platform.

1. Check platform and control console for damage, loose or missing part s , and security.

2-4 – JLG Lift – 3120742

SECTION 2 - PREPARATION AND INSPECTION

2. Check control switches and levers for damage, loose or missing parts, and security. Assure that lever and lever lock functions properly.

3. Check control switches, levers and electrical connections for tightness and evidence of corrosion, and wiring for defects and chafing damage. Assure that switches function properly.

4. Check footswitch for damage, loose or missing parts, and security. Assure that footswitch functions properly and that wiring has no defects or chafing.

5. Check (35/n35/40/n40/45 electric) platform rotator mechanism for lubrication. Check hydraulic rotator reservoir for leakage, damage, and security.

NOTE: Check all DANGER, WARNING, CAUTION, and

INSTRUCTION placards for legibility and security on the entire machine

TO AVOID INJURY, DO NOT OPERATE M ACHINE IF ALL PL ACARDS ARE NOT ON THE MACH INE OR ARE D EFACED AN D NOT READABLE. USE OF MACHINE WITHO UT CORRECT PLACARDS.IS A SAFETY VIOLATION

2.4 DAILY WALK-AROUND INSPECTION

It is the operators responsibilit y to inspect the machine before the start of each workday. It is recommended that each operator inspect the machine before operation, even if the machine has already been put into service under another operator. This Daily Walk-Around Inspection is the preferred metho d of inspection.

These checks are also to be performed after maintenance has been performed on the machine.

In addition to the Daily Walk-Around Inspection, be sure to include the following as part of the daily inspection:

1. Overall cleanliness.

4. Machine Log. Ensure a machine operating record or log is kept,

check to see that it is current and that no entries have been left uncleared, leaving machine in an unsafe condition for opera tion.

5. Start each day with a full fuel tank.

TO AVOID INJURY, DO NOT OPERATE A MACHINE UNTIL ALL MALFUNCTIONS HAVE BEEN CORRECTED. USE OF A MALFUNCTIONING MACHINE IS A SAFETY VIOLATION.

TO AVOID POSSIBLE INJURY, BE SURE MACHINE POWER IS "OFF" DURING WALK-AROUND INSPECTION.

NOTE: Check boom limit switches on upright for proper

operation and security, both visually and manually. The lower switch cuts out drive speed when the lower boom is above horizontal. The upper switch cuts out drive speed when the upper boom is above horizontal. Only creep drive speed will continue to function.

6. Check platform footswitch for proper operation. Switch must be released to start engine and depressed to operate machine.

7. Check that drive brakes hold when machine is driven up a grade not greater than specified on the serial number placard and stopped.

NOTE: On new machines, those recently overhauled, or

after changing hydraulic oil, operate all systems a minimum of two complete cycles and recheck oil level in reservoir.

8. Assure that all items requiring lubrication are serviced. Refer to Lubrication Chart, Figure 2-3, for specific requirements.

Check all standing surfaces for oil, fuel and hydraulic oil spillage and foreign objects. Ensure overall cleanliness.

2. Placards. Keep all information and operating placards clean

and unobstructed. Cover when spray painting or shot blasting to protect legibility.

3. Operator’s and Safety Manual. Ensure a copy of this manual and the ANSI A92.5-

1992 Responsibilities, are enclosed in the manual storage box.

3120742 – JLG Lift – 2-5

SECTION 2 - PREPARATION AND INSPECTION

Figure 2-3. Daily walk-around Inspection. (Sheet 1 of 3)

2-6 – JLG Lift – 3120742

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